Direct-acting pressure regulator

ABSTRACT

A pressure regulator having a housing with an inlet port and an outlet port. A plug is located within the housing and dividing the housing into an upper chamber and a lower chamber, with the upper and lower chamber being connected by a vent. The plug includes a fluid path between the inlet port and the bore. A yoke is adapted selectively close the fluid path in the plug. A diaphragm is located in the upper chamber and is connected to the yoke. A biasing member biases the yoke to open the fluid path through the plug. The diaphragm is configured to move the yoke to open the fluid path when pressure in the lower chamber and vented to the upper chamber through the vent is above a predetermined amount. The pressure regulator can also include a second biasing member used to positively close the fluid path through the plug.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application is a continuation-in-part of U.S.application Ser. No. 09/898,571 filed on Jul. 3, 2002, entitledDIRECT-ACTING PRESSURE REGULATOR, now U.S. Pat. No. ______, the entirecontents of which are hereby incorporated herein by reference, whichclaims priority to Provisional Patent Application Ser. No. 60/216,533,filed on Jul. 7, 2000 entitled DIRECT-ACTING PRESSURE REGULATOR.

BACKGROUND AND GENERAL SUMMARY OF THE INVENTION

[0002] This invention is applicable to a wide range of gaspressure-regulating applications, but is designed for particularlyadvantageous use in propane outdoor cooking appliance applications.

[0003] Heretofore, the gas pressure output of a pressure regulator hasbeen controlled by applying the inlet pressure against a flexiblediaphragm surface area that is balanced with a spring force set at oradjusted to the desired output gas pressure. Most regulators usingflexible diaphragms, however, have not had a direct-acting mechanismbetween the regulating valve and the diaphragm. Therefore, more partsare needed to control the flow of the gas, and regulation is often notas well controlled and accurate as desired. Also, the pressureregulators had to be large and expensive because of all of the elementsneeded to control the gas pressure. Furthermore, such pressureregulators typically require gas pressure in the outlet gas line tooperate the regulating device and to shut off the flow of gas. If apositive shut off is required as a safety measure, a separate shut-offvalve had to be placed at the outlet of the regulator to prevent theflow of gas downstream. Such a separate shut-off valve adds furtherexpense.

[0004] Accordingly, an apparatus which avoids the aforementioneddisadvantages and has the aforementioned desired features has long beendesired.

OBJECTS OF THE INVENTION

[0005] Broadly stated, the principal objects of the invention includeproviding a new and novel type of gas pressure regulator particularlywell-suited for use in propane outdoor cooking appliance applicationsand the like, different from the type customarily used heretofore inthis field, having novel and advantageous structures and features whichprovide significantly improved results. A further object of theinvention is to provide an enhanced-performance pressure regulatorhaving novel and advantageous physical componentry which cooperativelyprovides substantially and uniquely improved results and enables use ofvery small inlet orifice diameter, small diaphragm diameter and smalloverall regulator size, providing for reduced costs as well asimplementation advantages and improved operational results.

[0006] A still further and more particular object of the invention is toprovide an improved pressure regulator valve having novel internalcomponentry. Another important object of the invention is to provide anenhanced-performance, low-cost regulator that lends itself effectivelyto the use of automated manufacturing equipment and provides for ease ofassembly. A further object of the invention is to provide anenhanced-performance pressure regulator having novel and advantageousphysical componentry which cooperatively provides substantially improvedand uniquely advantageous physical results and enables use of a verysmall overall regulator size, providing for reduced costs as well asimplementation advantages. Another object of the present invention is toprovide a pre-assembly orifice plug and yoke component that can beinstalled into a pressure regulator body easily. Additional objects ofthe invention, as well as additional advantages thereof, will becomeapparent following consideration of the ensuing disclosure.

[0007] These and other features, advantages and objects of the presentinvention will be further understood and appreciated by those skilled inthe art by reference to the following specification, claims and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The following brief description of the figures, and the relatedfigures themselves, exemplifies a particular preferred embodiment of theinvention constituting the best mode presently contemplated. As will beunderstood, other embodiments of the invention as well as changes andvariations in the particular structure shown in these figures are nodoubt possible, and may very well suggest themselves to those skilled inthe art after studying this disclosure and these figures.

[0009]FIG. 1 is a perspective representation of an assembled pressureregulator in accordance with the invention;

[0010]FIG. 2 is an enlarged cross-sectional side view of the pressureregulator in accordance with the invention;

[0011]FIG. 3 is a further enlarged cross-sectional side view of thelower cylindrical body, orifice plug and yoke assembly in accordancewith the present invention;

[0012]FIG. 4 is a similarly enlarged cross-sectional side view of thelower cylindrical body, orifice plug and yoke assembly rotated 90° fromthe position shown in FIG. 3;

[0013]FIG. 5 is an isometric view of the orifice plug, disc holder andelastic diaphragm in accordance with the present invention;

[0014]FIG. 6 is an isometric view of the disc holder in accordance withthe present invention;

[0015]FIG. 7 is a cross-sectional view of the pressure regulatoraccording to a second embodiment of the present invention;

[0016]FIG. 8 is an enlarged cross-sectional side view of the pressureregulator in accordance with a third embodiment of the invention;

[0017]FIG. 9 is an enlarged cross-sectional front view of the pressureregulator in accordance with the third embodiment of the invention;

[0018]FIG. 10 is a perspective view of a disc holder of the thirdembodiment of the present invention;

[0019]FIG. 11 is a top view of the disc holder of the third embodimentof the present invention;

[0020]FIG. 12 is a cross-sectional view of the disc holder of the thirdembodiment of the present invention taken along the line XII-XII of FIG.11;

[0021]FIG. 13 is a cross-sectional view of the disc holder of the thirdembodiment of the present invention taken along the line XIII-XIII ofFIG. 11;

[0022]FIG. 14 is a perspective view of a diaphragm of the thirdembodiment of the present invention;

[0023]FIG. 15 is a top view of the diaphragm of the third embodiment ofthe present invention; and

[0024]FIG. 16 is a side view of the diaphragm of the third embodiment ofthe present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

[0025] For purposes of description herein, the terms “upper,” “lower,”“right,” “left,” “rear,” “front,” “vertical,” “horizontal,” andderivatives thereof shall relate to the invention as oriented in FIG. 1.However, it is to be understood that the invention may assume variousalternative orientations, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings and described in thefollowing specification are simply exemplary embodiments of theinventive concepts generally defined in the appended brief statements ofthe invention. Hence, specific physical details and characteristicspresent in the embodiments disclosed herein are not to be considered aslimiting, unless expressly stated otherwise.

[0026] The reference number 10 (FIG. 1) generally designates a pressureregulator embodying the present invention. In the illustrated example,pressure regulator 10 has a smaller upper body 12 (sometimes called the“bonnet”) and a larger lower body 14. The upper body 12 and the lowerbody 14 may be substantially cylindrical. The lower body 14 is connectedto the upper body 12 by mechanically deforming, or crimping, anupstanding flange 17 on the outside of the upper portion 13 of the lowerbody 14 over the outer flange 16 (FIG. 2) of the upper body 12. Thecrimp could also be reversed with a downward flange on the outside ofthe lower end of the upper body 12 and an outer flange on the lower body14. Alternatively, the smaller upper body 12 can have an outer flange ata lower end, which connects to the upper portion 13 of lower body 14 bya plurality of threaded fasteners. Protruding from the top of upper body12 is an adjustment cap 20 for the pressure regulator 10, the functionof which is described below. The adjustment cap 20 has a top portion 21and a downwardly depending skirt 23. The outer surface of lower body 14has an inlet port 22 and an aligned outlet port 24 (FIGS. 1 and 2). Inuse, the inlet port 22 is connected to a source of fuel, e.g., gas (notshown), and the outlet port is connected to an outdoor cooking appliance(not shown).

[0027] Referring to FIGS. 2-4, the upper portion 13 of the lower body 14has a stepped-diameter cylindrical recess or cavity 25 which opensthrough the top of lower body 14 and receives an orifice plug 26. Theorifice plug cavity 25 communicates with the inlet port 22 through asmall-diameter inlet channel 32, and communicates with the outlet port24 through an outlet channel 34. The inlet channel 32 and the outletchannel 34 are aligned with the inlet port 22 and the outlet port 24,respectively. The illustrated orifice plug cavity 25 is made of fiveprogressively smaller-diameter areas which form a first circular ledge28 near the top of the lower body 14, a second circular ledge 29 belowthe first ledge 28, a third circular ledge 35 above inlet channel 32 andbelow the second ledge 29, a fourth circular ledge 30 below the inletchannel 32 but above the outlet channel 34 and a bottom 33 aligned withthe outlet channel 34. The second ledge 29 supports the orifice plug 26within cavity 25. Cavity 25 also has a secondary port 36 opening intothe second ledge 29 and connecting the outlet port 24 to cavity 25.

[0028] The illustrated orifice plug 26 is of stepped cylindricalconfiguration, with three progressively smaller-diameter portionscorresponding to the cavity 25 noted above. The orifice plug 26 isinserted into cavity 25 to extend below the fourth ledge 30, but abovethe bottom 33 of cavity 25. A top cylindrical portion 71 of the orificeplug 26 is located below the first ledge 28 and just above the secondledge 29, the cylindrical portion 71 having a semicircular notch 41 inits outer circumferential wall. The notch 41 allows the secondary port36 to communicate with an area of cavity 25 located above the orificeplug 26. A pair of spaced O-rings 39 a, 39 b are positioned around theoutside of the orifice plug 26 to support the orifice plug 26 anddirectly seal an area of cavity 25 above orifice plug 26 from the inletchannel 32 and the outlet channel 34. O-ring 39 a is supported on thethird ledge 35 and O-ring 39 b is supported on the fourth ledge 30.Therefore, the top cylindrical portion 71 of orifice plug 26 restsdirectly on the second ledge 29 at an outside circumference and on theO-ring 39 a within the outside circumference. Likewise, the middle ringof orifice plug 26 rests directly on O-ring 39 b on the fourth ledge 30.

[0029] In the illustrated example (FIGS. 2-4), the orifice plug 26 hasan L-shaped gas flow channel 43 which extends perpendicularly toward andbetween a pair of axially parallel through-holes 38. The channel 43 hasa first end 45 adjacent and substantially parallel with the inletchannel 32, an elbow 37 at the axis of the orifice plug 26, an axiallyextending portion and a second opening 47 adjacent the bottom 33 ofcavity 25 and substantially transverse to the inlet channel 32. Thechannel 43 therefore connects the inlet channel 32 to the outlet channel34. Moreover, the channel 43 opens into the bottom 33 of the cavity 25at a seat area 40 on the bottom of orifice plug 26. Therefore, thenormal fluid path of a pressurized fluid through the pressure regulator10 starts with the fluid entering the inlet port 22 and flowing into theinlet channel 32. The pressurized fluid then passes laterally into thechannel 43 of the orifice plug 26, takes a turn at the elbow 37 andexits the orifice plug 26 in an axial direction at seat 40 into thebottom 33 of the orifice plug cavity 25. The pressurized fluid will thenfinally exit the pressure regulator 10 in a lateral direction throughthe outlet channel 34 and the outlet port 24.

[0030] In the illustrated preferred embodiment, a yoke assembly 42 (FIG.4) is integrally assembled with the orifice plug 26 and extends throughthe two substantially parallel through-holes 38. The yoke assembly 42includes a head 44, a thrust washer 46, two spaced suspension arms 48and a disc holder 50. The disc holder 50 (FIG. 6) is a substantiallyrectangular bar that includes a valve disc 52 located in a recess in thetop of the disc holder 50. The disc holder 50 and disc 52 are locatedadjacent to the bottom face of orifice plug 26. As described in moredetail below, the disc 52 is configured to come into contact with seat40 to prevent and/or restrict gas flow through the pressure regulator 10depending upon the variable spacing therebetween. The disc 52 ispreferably somewhat resilient and made of a synthetic rubber. The twosuspension arms 48 extend slidably through the two substantiallyparallel through-holes 38 of orifice plug 26 and are attached to thedisc holder 50 on opposite sides of the disc recess in the disc holder50. The two suspension arms 48 preferably have a diameter of about 0.1inch and are secured to the disc holder 50 by ultrasonic welding orother such means (including fasteners). The washer 46 is attached to thetwo suspension arms 48 on their ends opposite the disc holder 50. Theyoke assembly 42 is thereby movably connected to the orifice plug 26,with the orifice plug 26 between the washer 46 and the disc holder 50.The yoke head 44 is a cylinder attached coaxially to the top of thewasher 46 on a planar face thereof opposite the two suspension arms 48.The head 44, the thrust washer 46 and the two spaced suspension arms 48of the yoke assembly 42 are preferably integrally formed.

[0031] The illustrated yoke assembly 42 moves linearly in the axialdirection by sliding movement of the suspension arms 48 through the twosubstantially parallel through-holes 38 in the orifice plug 26. AnO-ring 49 surrounds each of the suspension arms 48 in each of the twosubstantially parallel through-holes 38. The O-rings 49 are stationarywithin the orifice plug 26 and seal a fluid path through the twosubstantially parallel through-holes 38. The O-rings 49 also providefriction on the yoke assembly 42 as the yoke assembly 42 cycles up anddown. The O-rings 49 therefore create a damping effect to contain thepossibility of harmonic motion of the yoke assembly 42 within theorifice plug 26. The yoke assembly 42 may have a vertical movementdistance 77 of about 0.020 inches to 0.050 inches. Most preferably, theyoke assembly 42 has a vertical movement distance of 0.030 inches. Whenthe yoke assembly 42 is at the top of its allowable movement, the disc52 in the disc holder 50 covers the flow orifice and seat 40 and stopsall flow through the channel 43, and therefore, through the pressureregulator 10. When the yoke assembly 42 is at the bottom of its stroke,the flow orifice/seat 40 is uncovered and open, whereby gas or otherfluids can flow freely through the pressure regulator 10. Preferably,the orifice plug 26 and the yoke assembly 42 are made of plastic. Mostpreferably, the orifice plug 26 is made of a polyester polymer and theyoke assembly 42 is made of an acetyl polymer.

[0032] In the illustrated example, the pressure regulator 10 has anelastic diaphragm 56 connected to the yoke assembly 42. The elasticdiaphragm 56 is configured as a washer with top and bottom planar faceswith an axial hole that receives the yoke head 44 of the yoke assembly42. Moreover, the outer circumference of the elastic diaphragm 56 issupported on the first ledge 28 of the orifice plug cavity 25 in thelower body 14. The elastic diaphragm 56 also has a downwardly dependingtongue 55 that fits with a circular groove 57 on the first ledge 28 ofthe cavity 25 in order to properly align and support the elasticdiaphragm 56. The cavity 25 therefore has an open cylindrical area thatis located below the elastic diaphragm 56 and above the orifice plug 26.A pressure plate 58 is also attached to the yoke assembly 42. Thepressure plate 58 is located within a circular cavity 61 (FIG. 2) in theupper body 12 and has an axial opening that receives the yoke head 44.The pressure plate 58 is joined to the elastic diaphragm 56 and the yokeassembly 42 by a retaining nut 66 which engages the outside of the yokehead 44, thereby clamping the elastic diaphragm 56 between the pressureplate 58 and washer 46 and fastening these components to yoke assembly42 as an operating unit.

[0033] The illustrated adjustment cap 20 of the pressure regulator 10includes a circular adjustment collar 94 attached to the bottom of thetop portion 21 of the cap 20 and located within the circular cavity 61of the upper body 12. The adjustment collar 94 has an open annular tube96 that extends out of the opening 59 in the top of the upper body 12.The bottom of the top portion 21 of the cap 20 is attached to the top ofthe open annular tube 96. The open annular tube 96 also has an L-shapedleg 98 extending from the side of the open annular tube 96. The leg 98has a first portion 101 extending transversely of the outside wall ofthe cylindrical body 88 and a downward depending annular second portion103 that is substantially perpendicular to the first portion 101 of theleg 98. Therefore, a recess 104 is located within the adjustment collar94 between the annular second portion 103 of the L-shaped leg 98 and theopen annular tube 96 of the adjustment collar 94, but below the firstportion 101 of the L-shaped leg 98. The illustrated outside periphery offirst portion 101 of the leg 98 has an O-ring 120 in a recess adjacentthe inside wall 99 of the circular cavity 61 in order to seal thecircular cavity 61 from the contaminants. The second portion 103 of theleg 98 has outside threads 100 that mate with inside threads 102 of theinside wall 99 of the circular cavity 61 of the upper body 12 a. Asexplained in more detail below, rotating the cap 20 will force theadjustment collar 94 down to positively open the pressure regulator 10.

[0034] In the illustrated example, the pressure regulator 10 has a largespring 64 that extends upwardly into the recess 104 of the adjustmentcollar 94, to the top of the latter. An upper washer 62 is located atthe top of the large spring 64 and the plate 58 is located at the bottomof the large spring 106 thereby allowing the large spring 106 tocompress within the upper body 12. A lower washer 110 is locateddirectly above the plate 58 a of the yoke assembly 42 a and the elasticdiaphragm 56 a. The illustrated large spring 64 operates to positivelyopen the pressure regulator 10 by pressing down on the plate 58 and thuson diaphragm 56. Therefore, the cap 20 is connected to the valve disc 52through the spring 64, the pressure plate 58, the nut 66, the elasticdiaphragm 56, the orifice plug 26 and the yoke assembly 42.

[0035] The illustrated pressure regulator 10 is constructed by firstassembling the yoke assembly 42 and the orifice plug 26 into anoperative component. The elastic diaphragm 56 and the plate 58 are thenconnected to the yoke assembly 42 and the orifice plug 26 with theretaining nut 66. The O-rings 39 a, 39 b are then placed around theorifice plug 26 and the orifice plug 26 and O-rings 39 are inserted intothe cavity 25. The orifice plug 26 is therefore situated on the secondledge 29 and the fourth ledge 30, and the flexible diaphragm 56 is thensituated on the first ledge 28. The spring 64 is then placed on thepressure plate 58 within the circular cavity 61. This assembles the yokeassembly 42, the upper body 12, the cap 20, the plate 58, the elasticdiaphragm 56 and the orifice plug 26 together. The upper body 12 and thelower body 14 are secured together by crimping the upstanding flange onthe outside of the upper portion 13 of the lower body 14 over the outerflange 16 of the upper body 12. The elastic diaphragm 56 is held inplace around its circumference by a downwardly depending flange 68located on the inside of the outer flange 16 of the upper body 12 whichclamps the diaphragm against first ledge 28, thereby leaving an openspace in the orifice plug cavity 25 between the bottom face of theelastic diaphragm 56 and the top of the orifice plug 26. This spaceprovides the pressure-regulating chamber.

[0036] In the illustrated example, the pressure regulator 10 willregulate the fluid pressure to the outlet port 24 by allowing fluid toflow through the inlet port 22 and into the inlet channel 32. The fluidthen passes into the channel 43 of the orifice plug 26 and exits theorifice plug 26 at the seat 40 into the bottom 33 of the orifice plugcavity 25. The fluid will then finally exit out of the pressureregulator 10 through the outlet channel 34 and the outlet port 24. Thefluid in the outlet port 24 will also enter the orifice plug cavity 25through the secondary port 36 and the notch 41 in the orifice plug 26.The fluid in the orifice plug cavity 25 from the secondary port 36 willenter the orifice plug cavity 25 above the orifice plug 26 and below theelastic diaphragm 56, and will apply a pressure to the elastic diaphragm56 which, when balanced against the spring force applied to the top ofthe diaphragm, determines the pressure in the outlet port 24. In asteady state condition, the elastic diaphragm 56 will keep the disc 52sufficiently away from the seat 40 to allow fluid to flow at a nearconstant pressure through the pressure regulator. However, if thepressure of the fluid at the outlet port 24 rises, it will force theelastic diaphragm 56 and the spring 64 in the circular cavity 61 upward.When the elastic diaphragm 56 is forced upwards, the yoke assembly 42and disc holder 50 will move upward and force the disc 52 into contactwith the seat 40, thereby decreasing the flow of fluid to the outletport 24. When the pressure in the outlet port 24 and the orifice plugcavity 25 below the elastic diaphragm 56 is reduced, the elasticdiaphragm 56 under the force of the spring 64 above it will movedownward, thereby lowering the yoke assembly 42, including disc holder50 and disc 52. Fluid will then again flow through the pressureregulator 10. When the adjustment cap 20 is rotated to move downwardtowards the top of the upper body 12, the attached adjustment collar 94will also rotate downward. The downward movement of the adjustment cap20 and the adjustment collar 94 will thereby compress the large spring64 between the first portion 101 of the L-shaped leg 98 and the plate58. Since the adjustment collar 94 captures the large spring 64 at itstop end, the large spring 64 is forced to compress downwardly againstthe plate 58 connected to the yoke assembly 42. The large spring 64 willtherefore create a downward force against the top of the plate 58 of theyoke assembly 42 as the large spring 64 is compressed. If the largespring 64 is compressed beyond a predetermined point, the large spring64 will force the washer 46 to move downward. The compression of thelarge spring 64 will therefore force the yoke assembly 42 downward.Therefore, rotating the adjustment cap 20 to move it downward will forcethe large spring 64 and yoke assembly 42 downward due to compression ofthe large spring 64. Consequently, the disc 52 will move away from theseat 40, thereby opening the pressure regulator 10. Hence, rotating theadjustment cap 20 to move it downward will increase the pressureregulator 10 outlet flow.

[0037] Every time the adjustment cap 20 is rotated downward, a newsteady-state condition is created for the pressure regulator 10, wherebythe disc 52 is located a further distance from the bottom face and seat40 of the orifice plug 26, thereby allowing more fluid to pass throughthe pressure regulator 10. As discussed previously, however, if thepressure of the fluid leaving the outlet port 24 rises above thedownward force of the large spring 106 in each such steady statecondition, the fluid pressure in the outlet port 24 and in the orificeplug cavity 25 below the elastic diaphragm 56 and above the orifice plug26 will force the elastic diaphragm 56 upwards. When the elasticdiaphragm 56 is forced upwards, the attached yoke assembly 42 and discholder 50 will move upwards and force the disc 52 toward the seat 40,thereby decreasing the flow of fluid into the outlet port 24. When thepressure in the outlet port 24 and the cavity 25 below the elasticdiaphragm 56 decreases to a desired level, the large spring 64 will movethe elastic diaphragm 56 lower, thereby lowering the yoke assembly 42,disc holder 50 and disc 52. Fluid flow will then increase through thepressure regulator 10.

[0038] The reference number 10 a (FIG. 7) generally designates a secondembodiment of the present invention, comprising a pressure regulatorhaving additional features. Pressure regulator 10 a is essentiallysimilar to the previously described pressure regulator 10 in many ways,similar parts appearing in FIG. 1 and FIG. 8 respectfully arerepresented by the same, corresponding reference numeral, except for thesuffix “a” in the numerals of the latter. The lower body 14 a, cap 20,the orifice plug 26 a, the yoke assembly 42 a and the elastic diaphragm56 a are configured and function substantially the same in both thefirst and the second embodiments of the present invention. The yokeassembly 42 a, however, of the illustrated pressure regulator 10 a ofthe second embodiment has an opening and closing cylinder 86 replacingthe head 44 of the pressure regulator 10 of the first embodiment. Theopening and closing cylinder 86 includes a cylindrical body 88, and asmaller diameter pin 92 that extends from the top of the cylindricalbody 88. The cylindrical body 88 of the opening and closing cylinder 86extends upward from the pressure plate 58 a to an area adjacent the topof the upper body 12 a.

[0039] The illustrated pressure regulator 10 a also has a shut-offspring 112 that is located within the open tube 96 a that surrounds thetop portion of the cylindrical body 88 of the opening and closingcylinder 86. The shut-off spring 112 is located between a collar 114attached to the smaller diameter pin 92 at the top of the opening andclosing cylinder 86 and an integral flange 116 located at the bottom ofthe open annular tube 96 a. The illustrated shut-off spring 112 operatesto positively close the pressure regulator 10 a by pressing upwardly onthe collar 114 and, thus, on the opening and closing cylinder 86.

[0040] When the cap 20 a is rotated to move away from the top of theupper body 12 a, the adjustment collar 94 a will likewise rotate upward.The upward movement of the cap 20 a and the adjustment collar 94 a willcompress the shut-off spring 112 between the collar 114 and the flange116. The upward movement of adjustment collar 94 a decompresses spring64 a, while compressing the shut-off spring 112 against the collar 114on pin 92 of the opening and closing cylinder 86. The shut-off spring112 will therefore create an upward force against the top of the stopcollar 114 and the attached opening and closing cylinder 86. If theshut-off spring 112 is compressed beyond a predetermined point, theshut-off spring 112 will force the opening and closing cylinder 86 tomove upward. Therefore, rotating the cap 20 a upward will force thecollar 114 and the opening and closing cylinder 86 upward. Consequently,the disc 52 a will move towards the seat 40 a, closing the pressureregulator 10 a. Hence, rotating the cap 20 a upward will positivelyclose the pressure regulator 10 a. Therefore, the pressure regulator 10a of the second embodiment can be positively shut off to the flow offluid through the plug 26 a without any gas pressure under the elasticdiaphragm 56 a.

[0041] The reference number 10 b (FIGS. 8-9) generally designates athird embodiment of the present invention, comprising a pressureregulator having additional features. Pressure regulator 10 b isessentially similar to the previously described pressure regulator 10 ain many ways, similar parts appearing in FIG. 7 and FIGS. 8-9respectfully are represented by the same, corresponding referencenumeral, except for the suffix “b” in the numerals of the latter. Theillustrated pressure regulator 10 b includes an orifice plug 26 b withan elongate top cylindrical portion 71 b, an additional O-ring 202 and adifferent connection between the upper body 12 b and the lower body 14 bto accommodate the elongate top cylindrical portion 71 b of the orificeplug 26 b. The pressure regulator 10 b further includes anotherembodiment of the pressure plate 58 b and another embodiment of the discholder 50 b and valve disc 52 b.

[0042] In the illustrated example, the elongate top cylindrical portion71 b of the orifice plug 26 b is positioned directly between the upperbody 12 b and the lower body 14 b. As the upper body 12 b is connectedto the lower body 14 b, the elongate top cylindrical portion 71 b iscompressed between the upper body 12 b and the lower body 14 b tomaintain the orifice plug 26 b is position. The elongate top cylindricalportion 71 b includes an aperture 206 instead of a notch 41 as in thefirst embodiment and the second embodiment of the pressure regulator forallowing the secondary port 36 b to communicate with an area of cavity25 b located above the orifice plug 26 b. The orifice plug 26 b alsoincludes an inverted channel 208 for accommodating the O-ring 202 on asecond circular ledge 29 b of the lower body 14 b.

[0043] The illustrated disc holder 50 b (FIGS. 10-13) is connected tothe two spaced suspension arms 48 b and is configured to come intocontact with a seat 40 b to prevent and/or restrict gas flow through thepressure regulator 10 b depending upon the variable spacing therebetweenin the same manner as described in the second embodiment of the pressureregulator 10 a. The disc holder 50 b includes a substantiallyrectangular plate 210 having a pair of circular openings 212 havinglocking fingers 214 extending into the openings 212 for locking thesuspension arms 48 b within the openings 212. The locking fingers 214are configured to deflect as the suspension arms 48 b are inserted intothe openings 212 and then dig into the outer surface of the suspensionarms 48 b to prevent the removal of the suspension arms 48 b from theopenings 212. The rectangular plate 210 of the disc holder 50 b alsoincludes a pair of upstanding tabs 216. The valve disc 52 b ispositioned between the tabs 216 to prevent the valve disc 52 b frommoving laterally on the rectangular plate 210. The valve disc 52 b isalso located between the suspension arms 48 b (see FIG. 9) to preventlongitudinal movement of the valve disc 52 b. Accordingly, the valvedisc 52 b is locked into position when the disc holder 50 b is connectedto the suspension arms 48 b. The disc holder 50 b is preferablyfabricated from a metal stamping process, although it is considered thatother methods and materials can be employed to manufacture the discholder 50 b.

[0044] In the illustrated example, the pressure plate 58 b (FIGS. 14-16)locks the diaphragm 56 b against the thrust washer 46 b of the yokeassembly 42 b. The pressure plate 58 b is substantially circular andincludes a central plate 218 having a central aperture 220. The pressureplate 58 b includes locking fingers 222 extending into the centralaperture 220 for locking the head 44 b of the yoke assembly 42 b withinthe central aperture 220. The locking fingers 222 are similar to thepreviously described locking fingers 214 and are configured to deflectas the head 44 b is inserted into the aperture 220 and then dig into theouter surface of the head 44 b to prevent the removal of the head 44 bfrom the central aperture 220.

[0045] The pressure regulator of the present invention provides asimplified and very compact design that can be incorporated into variousregulator designs with slight modifications and should not be consideredonly unique to the disclosed design. It should be noted that in theevent there is no downstream demand, gas pressure increases inside thechamber until the seat disk forms a seal on the valve seat, causing azero flow or lockup condition. In this regard, the described inventionalso includes a safety feature commonly referred to as pressure control.

[0046] As described previously, the mechanism of this device operates tocontrol output flow pressure to meet downstream demand. When demandincreases, outlet pressure decreases and this results in downwardmovement of the diaphragm and its related parts, including the yokeassembly, causing the seat disk to move incrementally away from theorifice and thereby allow more flow through the device to supply the newdemand at the same regulated pressure. This continues until the demandis satisfied and an equilibrium state is reached. Conversely, the sameevents occur in reverse for conditions of decreasing demand. Changes ininlet pressure and/or demand will cause the device to compensate byopening or closing the valve mechanism in response to and in accordancewith the new conditions, to again reach an equilibrium state.

[0047] The described invention provides consistent repeatableperformance over a wide range of inlet pressures and flow rates whilealso enabling significant reduction in orifice diameter and in diaphragmand overall regulator size. Furthermore, it accomplishes this by use ofa simplified mechanism that is less expensive to manufacture andassemble, while at the same time providing better operating results dueto the novel design, which substantially reduces function and regulatinginaccuracies due to mechanical tolerance variations and lost motioninherent in less directly acting mechanisms which characterize the priorart.

[0048] The foregoing detailed description is considered that of apreferred embodiment only, and the particular shape and nature of atleast some of the components in this embodiment are at least partiallybased on manufacturing advantages and considerations as well as on thosepertaining to assembly and operation. Modifications of this embodimentmay well occur to those skilled in the art and to those who make or usethe invention after learning the nature of this preferred embodiment,and the invention lends itself advantageously to such modification andalternative embodiments. Therefore, it is to be understood that theembodiment shown in the drawings and described above is providedprincipally for illustrative purposes and should not be used to limitthe scope of the invention, which is defined by the following claims asinterpreted according to the principles of patent law, including thedoctrine of equivalents.

[0049] It will be readily appreciated by those skilled in the art thatmodifications may be made to the invention without departing from theconcepts disclosed herein. Such modifications are to be considered asincluded in the following claims, unless these claims by their languageexpressly state otherwise.

We claim:
 1. A pressure regulator comprising: a housing having a bore,the housing including an inlet port and an outlet port fluidly connectedto the bore; a plug located within the housing and dividing the boreinto an upper chamber and a lower chamber, the plug includes a pair ofparallel through holes, the plug further including a channel fluidlyconnected to the inlet port, the channel including a valve seat fluidlyconnecting the inlet port to the bore; a yoke extending through the plugand being adapted to move relative to the plug, the yoke being connectedto a valve, the valve being adapted to selectively cover the valve seat,the yoke including a pair of parallel legs extending through the throughholes of the plug, the valve being interconnected to the legs adjacentthe valve seat; a diaphragm located in the upper chamber, the diaphragmbeing connected to the yoke; a vent fluidly connecting the upper chamberto the lower chamber; and a biasing member biasing the yoke through theplug such that the valve does not cover the valve seat; and wherein thediaphragm is configured to move against the biasing member when pressurein the lower chamber is above a predetermined amount, thereby forcingthe yoke to slide within the plug and the valve to cover the valve seatsuch that fluid is not able to pass through the inlet port of thehousing and the channel of the plug.
 2. The pressure regulator of claim1, wherein: the housing includes a lower housing member and an upperhousing member; the plug is located within the lower housing member; anda periphery of the diaphragm is located between the upper housing memberand the lower housing member.
 3. The pressure regulator of claim 2,wherein: the lower housing member includes a plurality of ledges; theplug includes a plurality of projections; at least one of theprojections of the plug are located on one of the ledges of the lowerhousing member.
 4. The pressure regulator of claim 3, wherein: at leastone O-ring is located between one of the ledges of the lower housingmember and one of the projections of the plug.
 5. The pressure regulatorof claim 4, wherein: the vent extends through the lower housing memberand one of the projections of the plug, thereby fluidly connecting thelower chamber to the upper chamber.
 6. The pressure regulator of claim1, wherein: the yoke further includes a valve holder extending betweenthe legs adjacent the valve seat; and the valve includes a discconnected to the valve holder of the yoke.
 7. The pressure regulator ofclaim 6, further including: an O-ring surrounding each of the pair ofparallel legs of the yoke; wherein each of the O-rings abuts against aninside wall of the through holes of the plug.
 8. The pressure regulatorof claim 1, further including: a cap connected to the housing, the capenclosing the bore to define an internal cavity between the housing andthe cap.
 9. The pressure regulator of claim 8, wherein: the cap isrotatably connected to the housing.
 10. The pressure regulator of claim9, wherein: the cap includes an adjustment collar adapted to engage thebiasing member; the biasing member is located between the cap and thediaphragm; rotation of the cap causes the cap to be alternatively movedtowards and away from the diaphragm; and rotation of the cap towards thebiasing member increases the predetermined amount and rotation of thecap away from the biasing member reduces the predetermined amount. 11.The pressure regulator of claim 9, wherein: a biasing member comprises afirst spring applying a first force to the yoke to bias the valve awayfrom the valve seat; further including a second spring applying a secondforce to the yoke to bias the valve towards the valve seat; whereinrotation of the cap away from the diaphragm can cause the valve to abutthe valve seat to positively stop fluid flow through the plug.
 12. Thepressure regulator of claim 11, wherein: the second spring is locatedbetween the adjustment collar and the yoke.
 13. The pressure regulatorof claim 1, wherein: the housing includes a lower housing member and anupper housing member; the plug is maintained in position between theupper housing member and the lower housing member.
 14. The pressureregulator of claim 1, wherein: the yoke further includes a valve holderextending between the legs adjacent the valve seat, the valve holderincluding a pair of openings configured to accept the pair of parallellegs of the yoke therein; and the valve includes a disc connected to thevalve holder of the yoke.
 15. The pressure regulator of claim 14,wherein: the valve holder includes locking fingers extending intoopenings of the valve holder, the locking fingers being configured todeflect as the legs are inserted into the openings and then dig into theouter surface of the legs to prevent the removal of the legs from theopenings.
 16. The pressure regulator of claim 1, further including: apressure plate connecting the diaphragm against the yoke, the pressureplate including a central aperture configured to accept a portion of theyoke.
 17. The pressure regulator of claim 16, wherein: the pressureplate includes locking fingers extending into the aperture, the lockingfingers being configured to deflect as the portion of the yoke isinserted into the aperture and then dig into the outer surface of theportion of the yoke to prevent the removal of the portion of the yokefrom the aperture.
 18. A pressure regulator comprising: a housing havinga bore, the housing including an inlet port and an outlet port fluidlyconnected to the bore; a plug located within the housing and dividingthe bore into an upper chamber and a lower chamber, the plug including achannel fluidly connected to the inlet port, the channel including avalve seat fluidly connecting the inlet port to the bore; a yokeextending through the plug and being adapted to move relative to theplug, the yoke being connected to a valve, the valve being adapted toselectively cover the valve seat; a diaphragm located in the upperchamber, the diaphragm being connected to the yoke; a vent fluidlyconnecting the upper chamber to the lower chamber; and a biasing memberbiasing the yoke through the plug such that the valve does not cover thevalve seat; and wherein the diaphragm is configured to move against thebiasing member when pressure in the lower chamber is above apredetermined amount, thereby forcing the yoke to slide within the plugand the valve to cover the valve seat such that fluid is not able topass through the inlet port of the housing and the channel of the plug;and wherein the yoke further includes a valve holder, the valve holderincluding at least one opening configured to accept a portion of theyoke therein, the valve holder including locking fingers extending intothe at least one opening of the valve holder, the locking fingers beingconfigured to deflect as the portion of the yoke is inserted into the atleast one opening and then dig into the outer surface of the portion ofthe yoke to prevent the removal of the portion of the yoke from the atleast one opening.
 19. The pressure regulator of claim 18, wherein: theplug includes a pair of parallel through holes; the yoke includes a pairof parallel legs extending through the through holes of the plug, thevalve being interconnected to the legs adjacent the valve seat; thevalve holder includes two openings; and the portion of the yokecomprises the pair of parallel legs.
 20. The pressure regulator of claim18, wherein: the housing includes a lower housing member and an upperhousing member; the plug is located within the lower housing member; anda periphery of the diaphragm is located between the upper housing memberand the lower housing member.
 21. The pressure regulator of claim 20,wherein: the lower housing member includes a plurality of ledges; theplug includes a plurality of projections; at least one of theprojections of the plug are located on one of the ledges of the lowerhousing member.
 22. The pressure regulator of claim 21, wherein: atleast one O-ring is located between one of the ledges of the lowerhousing member and one of the projections of the plug.
 23. The pressureregulator of claim 22, wherein: the vent extends through the lowerhousing member and one of the projections of the plug, thereby fluidlyconnecting the lower chamber to the upper chamber.
 24. The pressureregulator of claim 18, wherein: the plug includes a pair of parallelthrough holes; and the valve includes a disc connected to the valveholder of the yoke.
 25. The pressure regulator of claim 24, furtherincluding: an O-ring surrounding each of the pair of parallel legs ofthe yoke; wherein each of the O-rings abuts against an inside wall ofthe through holes of the plug.
 26. The pressure regulator of claim 18,further including: a cap connected to the housing, the cap enclosing thebore to define an internal cavity between the housing and the cap. 27.The pressure regulator of claim 26, wherein: the cap is rotatablyconnected to the housing.
 28. The pressure regulator of claim 27,wherein: the cap includes an adjustment collar adapted to engage thebiasing member; the biasing member is located between the cap and thediaphragm; rotation of the cap causes the cap to be alternatively movedtowards and away from the diaphragm; and rotation of the cap towards thebiasing member increases the predetermined amount and rotation of thecap away from the biasing member reduces the predetermined amount. 29.The pressure regulator of claim 27, wherein: a biasing member comprisesa first spring applying a first force to the yoke to bias the valve awayfrom the valve seat; further including a second spring applying a secondforce to the yoke to bias the valve towards the valve seat; whereinrotation of the cap away from the diaphragm can cause the valve to abutthe valve seat to positively stop fluid flow through the plug.
 30. Thepressure regulator of claim 29, wherein: the second spring is locatedbetween the adjustment collar and the yoke.
 31. The pressure regulatorof claim 18, wherein: the housing includes a lower housing member and anupper housing member; the plug is maintained in position between theupper housing member and the lower housing member.
 32. The pressureregulator of claim 18, wherein: the valve includes a disc connected tothe valve holder of the yoke.
 33. The pressure regulator of claim 18,further including: a pressure plate connecting the diaphragm against theyoke, the pressure plate including a central aperture configured toaccept a head of the yoke.
 34. The pressure regulator of claim 33,wherein: the pressure plate includes locking fingers extending into theaperture, the locking fingers being configured to deflect as the head isinserted into the aperture and then dig into the outer surface of thehead to prevent the removal of the head from the aperture.
 35. Apressure regulator comprising: a housing having a bore, the housingincluding an inlet port and an outlet port fluidly connected to thebore; a plug located within the housing and dividing the bore into anupper chamber and a lower chamber, the plug including a channel fluidlyconnected to the inlet port, the channel including a valve seat fluidlyconnecting the inlet port to the bore; a yoke extending through the plugand being adapted to move relative to the plug, the yoke being connectedto a valve, the valve being adapted to selectively cover the valve seat;a diaphragm located in the upper chamber, the diaphragm being connectedto the yoke; a vent fluidly connecting the upper chamber to the lowerchamber; and a biasing member biasing the yoke through the plug suchthat the valve does not cover the valve seat; and a pressure plateconnecting the diaphragm against the yoke, the pressure plate includinga central aperture configured to accept a portion of the yoke, thepressure plate further including locking fingers extending into theaperture, the locking fingers being configured to deflect as the portionof the yoke is inserted into the aperture and then dig into the outersurface of the portion of the yoke to prevent the removal of the portionof the yoke from the aperture; wherein the diaphragm is configured tomove against the biasing member when pressure in the lower chamber isabove a predetermined amount, thereby forcing the yoke to slide withinthe plug and the valve to cover the valve seat such that fluid is notable to pass through the inlet port of the housing and the channel ofthe plug; and
 36. The pressure regulator of claim 35, wherein: thehousing includes a lower housing member and an upper housing member; theplug is located within the lower housing member; and a periphery of thediaphragm is located between the upper housing member and the lowerhousing member.
 37. The pressure regulator of claim 36, wherein: thelower housing member includes a plurality of ledges; the plug includes aplurality of projections; at least one of the projections of the plugare located on one of the ledges of the lower housing member.
 38. Thepressure regulator of claim 37, wherein: at least one O-ring is locatedbetween one of the ledges of the lower housing member and one of theprojections of the plug.
 39. The pressure regulator of claim 38,wherein: the vent extends through the lower housing member and one ofthe projections of the plug, thereby fluidly connecting the lowerchamber to the upper chamber.
 40. The pressure regulator of claim 35,wherein: the plug includes a pair of parallel through holes; the yokeincludes a pair of parallel legs extending through the through holes ofthe plug, the yoke further includes a valve holder extending between thelegs adjacent the valve seat; and the valve includes a disc connected tothe valve holder of the yoke.
 41. The pressure regulator of claim 40,further including: an O-ring surrounding each of the pair of parallellegs of the yoke; wherein each of the O-rings abuts against an insidewall of the through holes of the plug.
 42. The pressure regulator ofclaim 35, further including: a cap connected to the housing, the capenclosing the bore to define an internal cavity between the housing andthe cap.
 43. The pressure regulator of claim 42, wherein: the cap isrotatably connected to the housing.
 44. The pressure regulator of claim43, wherein: the cap includes an adjustment collar adapted to engage thebiasing member; the biasing member is located between the cap and thediaphragm; rotation of the cap causes the cap to be alternatively movedtowards and away from the diaphragm; and rotation of the cap towards thebiasing member increases the predetermined amount and rotation of thecap away from the biasing member reduces the predetermined amount. 45.The pressure regulator of claim 43, wherein: a biasing member comprisesa first spring applying a first force to the yoke to bias the valve awayfrom the valve seat; further including a second spring applying a secondforce to the yoke to bias the valve towards the valve seat; whereinrotation of the cap away from the diaphragm can cause the valve to abutthe valve seat to positively stop fluid flow through the plug.
 46. Thepressure regulator of claim 45, wherein: the second spring is locatedbetween the adjustment collar and the yoke.
 47. The pressure regulatorof claim 35, wherein: the housing includes a lower housing member and anupper housing member; the plug is maintained in position between theupper housing member and the lower housing member.
 48. The pressureregulator of claim 35, wherein: the yoke includes a pair of parallellegs extending through the through holes of the plug; the yoke furtherincludes a valve holder extending between the legs adjacent the valveseat, the valve holder including a pair of openings configured to acceptthe pair of parallel legs of the yoke therein; and the valve includes adisc connected to the valve holder of the yoke.
 49. The pressureregulator of claim 48, wherein: the valve holder includes lockingfingers extending into openings of the valve holder, the locking fingersbeing configured to deflect as the legs are inserted into the openingsand then dig into the outer surface of the legs to prevent the removalof the legs from the openings.